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Thread: '78 810 heater core removal

  1. #1
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    '78 810 heater core removal

    My "new" 810 wagon has developed a leak in the heater core. Before I get into it, does any one have any insight or tips on getting it out? Car does have A/C so it may make a difference in removal. A/C system needs to be discharged anyway since the compressor froze up so figured I would do both the compressor and heater core at once.

  2. #2
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    Feb 2007
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    I removed my heater core box for maintenance a few years ago, but I first removed the evaporator enclosure because I had to repair a refrigerant leak (a fitting needed to be tightened). I believe you could remove the heater box without removing the evaporator but it would be a tight fit. The normally informative FSM is no help here.

    Some pointers:

    Remove the console for better access.

    Remove the ends of the heater hoses that attach in the engine compartment. Leave the other ends of the hoses attached to the core and water control valve.

    Remove the vent ducts where they fit into the heater box.

    Unscrew the bolts that secure the heater box to the firewall and pull it out just far enough to unplug the electrical connector and the vacuum lines. Then slide the box out the rest of the way pulling the heater hoses through the firewall.

    No need to mess with any cables as the lovers/ducts that are controlled by cables are self contained within the heater box. The remote located air inlet ducts are controlled by vacuum lines.

    My water control valve was leaking so I replaced it with a NOS one. Iím not sure if a new one is still available. My heater core was fine so I re-used it. I removed what was left of the old vent door foam and replaced it with self-adhesive foam I got from McMaster.com. I cleaned the insides of the box with 409 spray and finished up by re-lubing the cables with some silicone grease.

    The biggest problem was what to replace the heater hoses with. The 810 ones are NLA. What I did was to take the 280ZX heater hoses and cut them and combine them with some unknown heater hoses I had in my junk box. I used a brass sleeve and Oetiker clamps to join the hoses together. I think I took some photos of the "hybrid" heater hoses. I will look for them.

    Some of the aftermarket internet sources will claim they have the heater hoses for the 810, but do not be mislead. What they are selling is just a straight piece of generic hose (no pre-formed bends) the correct length.

  3. #3
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    Thanks for the insight and tips Steve, much appreciated. I'll pull it apart this week and see what is going on. I may need to remove the A/C portion (i'll check to see if it has a charge still) since the compressor needs to be replaced as well.

  4. #4
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    Check with Norm if you need a compressor. He may still have some new ones left:

    http://www.oem-surplus.com/nwp/810.htm

  5. #5
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    Thanks for that link. He was out of stock on the compressor but had my shift handle!!

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